Fluid Distribution Pressure Testing With Staged Pump Reduction
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Solution Overview
Problem
During pressure tests for fluid distribution systems in wellbore operations, there is a risk of overpressurization and fluid backlash, which can damage pumps and piping equipment.
Innovation Solution
The method involves conducting a pressure test by initially pressurizing the system with multiple pumping units to an initial pressure, then reducing the number of pumping units to minimize flow and kinetic energy, and finally using a single or fewer pumping units to reach a higher final pressure, thereby minimizing overpressurization and fluid backlash.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pumps continue to rotate after deactivating during pressure testing, then the pumps can maintain pressure control, but the pumps will overpressurize the piping and equipment causing damage
Solution Approach 1:
The patent extracts the harmful continuous rotation function from the pump system by introducing a clutch mechanism that decouples the motor from the pump shaft. This allows the motor to remain powered while the pump shaft is disengaged, preventing the pump from overpressurizing the system after the target pressure is reached.
Solution Approach 2:
The clutch mechanism is pre-configured to engage and disengage at specific operational stages. Before reaching the target pressure, the clutch is engaged to transmit power to the pump. After reaching the target pressure, the clutch automatically disengages to prevent further pressurization, thereby preventing damage before it occurs.
2Reliability
If pumps are used to pressurize fluid to target pressure during testing, then the system can be tested for leaks, but the pumps will cause fluid backlash and damage to the drive shaft
Solution Approach 1:
The clutch mechanism extracts the harmful reciprocating action from the pump system. By disengaging the clutch after the pump reaches its stroke endpoint, the system prevents the pump from reciprocating and creating fluid backlash that would otherwise damage the drive shaft during leak testing.
Solution Approach 2:
The clutch is pre-programmed to disengage at the precise moment the pump reaches its stroke endpoint during the pressurization phase. This preliminary action ensures that when the pump stops, the clutch is already disengaged, preventing any subsequent reciprocating motion that could cause fluid backlash and drive shaft damage.
3Productivity
If multiple pumping units are used to pressurize the system, then the system can reach target pressure faster, but the kinetic energy and flow increase causing overpressurization
Solution Approach 1:
The patent segments the pump system into multiple independent pumping units, each capable of operating separately. This allows the system to use multiple units for rapid pressurization during the testing phase, then individually control and deactivate each unit to prevent overpressurization, thereby maintaining both speed and safety.
Solution Approach 2:
The system dynamically adjusts the number of active pumping units based on the pressurization stage. During the initial phase, multiple units operate in parallel to achieve target pressure quickly. As the system approaches the target pressure, the system dynamically reduces the number of active units and engages the clutch mechanism to prevent overpressurization, optimizing both productivity and safety.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively minimizes overpressurization and fluid backlash, reducing the risk of damage to pumps and piping equipment while ensuring the integrity of the fluid distribution system during pressure testing.
Implementation Method 1
pressurizing the fluid distribution system with a fluid using an initial number of pumping units to an initial predetermined pressure, and further pressurizing the fluid distribution system with the fluid using a final number of pumping units to a final predetermined pressure
Implementation Method 2
After reaching the final pressure and discontinuing operation of the pumps, the fluid in the piping can expand and apply a force, by the now unpumped fluid expanding outward, back into the rotor, shaft and motor of the pump
Data Source
AI summary
A method for minimizing over pressurization during a pressure test of a fluid distribution system comprises a plurality of pumping units in fluid communication with a wellhead via a manifold. The method comprises pressurizing the fluid distribution system with a fluid using an initial number of pumping units to an initial predetermined pressure, and further pressurizing the fluid distribution system with the fluid using a final number of pumping units to a final predetermined pressure. The final number of pumping units is less than the initial number of pumping units.